Apparatus for making books

ABSTRACT

An improved apparatus for making books and other sheet material articles includes a main conveyor for transporting groups of signatures to a covering station. A cover conveyor transports covers to the covering station where they are sequentially applied to the groups of signatures in a known manner. A first cover feed assembly sequentially feeds covers to the cover conveyor. In the event of a malfunctioning of a first cover feed assembly, a second cover feed assembly is activated to feed a cover to the cover conveyor. A detector for detecting a malfunctioning of the first cover feed assembly is capable of detecting either a failure to feed a cover or the feeding of double covers. In the event that double covers are fed, the double covers are rejected and the second cover feed assembly is activated.

United States Patent [1 1 Miaskoff et al.

[ 1 June 18, 1974 APPARATUS FOR MAKING BOOKS Inventors: LeonardMiaskoff; David A. Reed,

both of Easton, Pa.

Assignee: Harris-lntertype Corporation,

Cleveland, Ohio Filed: May 7, 1973 Appl. No.: 357,608

US. Cl 11/3, 270/56, 270/58, 271/9, 156/364 Int. Cl. B42c 11/00 FieldofSearch 270/56, 58; 198/79, 80; 271/9, 57,58; 118/1, 156/362-364References Cited UNITED STATES PATENTS Sather et al .1. 270/58 PRO 0588COMPUTER 3,627,303 12/1971 Zeewy 270/56 Primary Examiner-LawrenceCharles [57] ABSTRACT An improved apparatus for making books and othersheet material articles includes a main conveyor for transporting groupsof signatures to a covering station. A cover conveyor transports coversto the covering station where they are sequentially applied to thegroups of signatures in a known manner. A first cover feed assemblysequentially feeds covers to the cover conveyor. In the event of amalfunctioning of a first cover feed assembly, a second cover feedassembly is activated to feed a cover to the cover conveyor. Adetector-for detecting a malfunctioning of the first cover feed assemblyis capable of detecting either a failure to feed a cover or the feedingof double covers. Inthe event that double covers are fed, the doublecover s 7 Claims, 4 Drawing Figures PATENTEDJUN 1 a 1914 SHEET 2 BF 3BACKGROUND OF THE INVENTION A known bookbinding system includes asignature conveyor assembly having'a plurality of clamps which gripgroups of signatures. The clamps carry the groups of signatures to afirst station where a rotary knife cuts off the folds at the backs ofthe signatures. The books are then sequentially conveyed to a secondstation where the backs of the books are roughened. At one or moregluing stations, glue is applied to the roughened backs of the books-Acover feeder is effective to sequentially feed open covers to a coveringstation in a registered relationship with the books. After the covershave been applied to the books, the covers are formed by a coverbreaker. The books are then delivered to trimmers for suitable trimmingoperations.

If the cover feeder in a known bindery fails to feed a cover to acovering station, the bindery is stopped and the malfunction of thecover feeding apparatus is corrected. If double covers are fed to thecovering station, a jam-up or other malfunction of the coveringapparatus may occur. Whether the covering apparatus fails to feed acover or feeds double covers, it is necessary to stop the bindery andinterrupt production in order to correct the fault.

SUMMARY OF THE PRESENT INVENTION The present invention provides anapparatus for use in covering books, magazines, catalogs, or similaritems. This apparatus includes a cover conveyor which sequentiallytransports covers to a covering station where they are applied to abook. A first cover feeder assembly is provided to feed covers to thecover conveyor. In the event of a malfunctioning of the first cover feedassembly, a second cover feed assembly is activated to feed covers tothe cover conveyor. A detector for detecting a malfunctioning of thefirst cover feed assembly is capable of detecting either a failure tofeed a cover or a feeding of double covers. In either case, the secondcover feed assembly is activated to feed a cover without interruptingoperation of the hindery.

Accordingly, it is an object of the invention to provide a new andimproved apparatus for covering books of double covers by the firstcover feed assembly.

BRIEF DESCRIPTION OF THE DRAWINGS The foregoing and other objects andfeatures of the present invention will become more apparent upon aconsideration of the following description taken in connection with theaccompanying drawings wherein:

FIG. 1 is a schematic illustration of an apparatus for making books;

FIG. 2 is a schematic illustration of a cover feed arrangement itilizedin a bindery of the book-making apparatus of FIG. 1;

FIG. 3 is a schematic illustration of a covering station where coversare applied to books; and

FIG. 4 is a schematic illustration of a second embodiment of invention.invention.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION A system 10 formaking books is illustrated in FIG. 1. This system includes a gatherer12 having a plurality of feed mechanisms 14 for feeding signatures fromsupply hoppers or pockets onto a main conveyor assembly 16. During acycle of operation of the gatherer 12, the feed mechanisms 14 areactivated by process computer 20 to feed the signatures in such a manneras to form different books or magazines for different subscribers inaccordance with predetermined criteria from known subscriberinformation, such as age, occupation, geographic location, etc. Thus, ifthe signatures are being grouped in accordance with geographic location,some of the feed mechanisms 14 would be operated to feed signatureswhile others would be ineffective to thereby provide a combination ofsignatures directed to a subscriber in a certain area, such as theNorth. If the subscriber lived in a southern area, the feed mechanisms14 would be effective to form a different combination of signatures.

The signatures are transported by the conveyor 16 to a binder 24 the hesignatures are bound into a book. The main conveyor 16 then transportsthe bound book to a trimmer 28 where the book is trimmed to a desiredsize in a known manner. Finally the conveyor 16 transports the bound andtrimmed book to a labeler to be addressed to the subscriber who is toreceive the particular combination of signatures contained in the book.The process computer 20 is utilized] to control the operation of thebinder 24, the trimmer 28 and labeler 30 in the manner disclosed inUnited States application Ser. No. 141,331 filed May 7, 1971, by DonaldC. Harder and Victoriano F. Rana and entitled Method and Apparatus forProducing Magazines or the Like.

When groups 32 of signatures enter the binder 24,

theyare held in an on edge orientation with their folded backs down by aclamp assemblies 34 (FIG. 2') of the type illustrated in US. Pat. No.3,132,360. The interconnected clamps 34 form a book conveyor 38 (FIG. 3)which is a part of the main conveyor assembly 16 and is utilized totransport the books through the binder 24 with the books in an uprightorientation. As the books move through the binder 24, a rotary knife(not shown) cuts off the signature folds and the backs are thenroughened. Adhesive is then applied to the backs of the books in a knownmanner.

After adhesive is then applied to the back of a book, a cover conveyor42 (FIG. 2) transports a cover 44 to a covering station 46 (FIG. 3)where the cover is applied to the back of the-book by suitableapplicator 48. Since the bindery operations for preparing signatures andbinding a cover onto a book are well-known, they will not be furtherdescribed herein to avoid prolixity of description. However, it shouldbe noted that the known bindery operations can be utilized to applycovers to magazines, booklets, or pamphlets.

A main feed mechanism 52 (FIG. 2) is provided in the binder 24 to feedcovers 44 to the cover conveyer 42. In accordance with the presentinvention, a secondary cover feed mechanism 56 is provided to feedcovers to the cover conveyer 42 in the event of a malfunction of themain cover feed mechanism 52. Therefore, if the main cover feedmechanism 52 should fail to feed a cover to the cover conveyor 42, thesecondary cover feed mechanism 56 will supply the conveyer 42 with acover so that'an uninterrupted stream of covers is conducted to thecovering station 46 by the cover conveyor 42 even if the main cover feedmechanism malfunctions.

The main cover feed mechanism 52 includes a conveyer 57 which transportsa stream of flat or open covers 44 to a feed station 58. A sucker 59 atthe feed station is connected with a source of low pressure through asolenoid operated valve 60. When a cover is to be fed, the valve 60 isopened under the control of the computer and a drive mechanism 61 movesthe sucker 59 through a feed stroke to feed an open cover into the nipof a pair of feed rollers 62.

After passing through the nip of the feed rollers 62, the cover moves toan inspection station 64. At the inspection station 64 a detector 66detects that a cover is being fed from the main feed mechanism 52 to thecover conveyer 42.

In the event of a failure of the main feed mechanism 52 to feed a coverto the inspection station 64, a signal is transmitted from the detector66 to the process computer 20 over leads 68. In response to this signal,the process computer 20 activates the secondary feed mechanism 56 tofeed a cover 44 to the cover conveyer 24 in the place which wouldnormally have been occupied by the cover which was not fed by the mainfeed mechanism 52. Thus, even though the main feed mechanism 52 shouldskip or fail to feed a cover, the secondary feed mechanism 56 feeds acover so that the cover conveyer 42 is effective to conduct a continuousstream of covers 44 to the covering station 46.

The secondary feedmechanism 56 includes a conveyer 70 which transportsthe covers to a feed station 71. When the process computer 20 activatesthe secondary feed mechanism 56, feed rollers 72 at the feed station 71feed one cover 44 into the vacant position on the cover conveyer 42resulting from a malfunction of the main feed mechanism 52. As this onecover is fed, the feeder and conveyer 70 are operated for a short periodof time to move a next succeeding cover to the feed station 71.

It is contemplated that under certain circumstances the main feedmechanism 52 may feed two covers rather than one. The detector assembly66 is of the caliper. type and is effective to detect the feeding ofmore than one cover. Upon the detecting of the feeding of more than onecover, a signal is transmitted over the leads 68 to the process computer20. Whereupon the process computer 20 activates a reject mechanism 76 toreject the double covers. In addition the process computer 20 willactivate the secondary feed mechanism '56 to feed a cover 44 to thecover conveyer 42 in place of the rejected double covers.

The reject mechanism 76 includes a divert gate 77 which is pivoteddownwardly, to the position shown in dashed lines in FIG. 2, to directthe double coversinto covers into reject or double cover receiving bin78. The divert gate 77 is constructed in a manner similar to thatillustrated in U.S. Pat. application Ser. No. 176,851 filed Sept. l,1971, by Frederick T. Anderson and David A. Reed and entitled Method andApparatus for Producing Magazines or the Like. Of course, other knowndivert or reject mechanisms, such as the one disclosed in U.S. Pat. No.2,991,603, could be used if desired.

The reject mechanism 76 includes a known drive mechanism, illustratedschematically at 79 in FIG. 2,

, which is activated by the computer 20 in response to detection ofdouble covers 44 by the detector assembly 66. Activation of thereversible drive mechanism 79 moves the gate 77 between the feedposition shown in solid lines in FIG. 2 and the divert position shown indashed lines in FIG. 2.

If the gatherer l2 malfunctions, a reject mechanism 82 (FIG. 1) isactivated to reject the defective book which results from themalfunction. The clamp assembly 34 associated with the rejected bookwill be empty when it arrives at the covering station 46. Of course, acover 44 should not be supplied for the empty clamp assembly.

When a book is rejected, the computer 20 renders the main and secondaryfeed mechanisms 52 and 56 ineffective to feed a cover for the emptyclamp assembly 34. This results in an opening in the stream of coverstransported by the cover conveyer 42 to the covering station 46. Due tothe coordination provided by the computer 20, the opening in the streamof covers arrives at the covering station 46 simultaneously with theempty clamp assembly 34.

When a book is rejected by reject mechanism 82, the resultingdiscontinuity in the flow of books to the binder 24 is noted by thecomputer 20. When the sucker 59 is to feed a cover to be associated withthe rejected book, the computer 20 effects operation of the valve to theclosed condition. Therefore, the main feed mechanism 52 does not feed acover to the cover conveyer 42 for association with the empty clampassembly 34.

The detector 66 will detect the failure of the main feed mechanism 52 tofeed a cover for association with the empty clamp assembly 34. Adisabling circuit in the computer 20 will then prevent activation of thefeed rollers 72. Therefore the secondary feed mechanism 56 isineffective to feed a cover. This results in an opening in the series ofcovers conducted to the covering station 46 by the cover conveyer 42.

In the embodiment of the invention illustrated in FIG. 2, the feedmechanisms 52 and 56 are effective to feed similar covers to the coverconveyer 42. However, it is contemplated that different covers may beused with different books. Thus, if the gatherer I2 assembles a book forone geographic area, such as a northern area, and a book for anothergeographic area, such as a southern area, the book intended for thenorthern subscriber has one cover while the book intended for thesouthern subscriber may have another cover.

Accordingly, in the embodiment of the invention illustrated in FIG. 4,three feed mechanisms are utilized to feed covers to the cover conveyer.One of these feed mechanisms feeds covers intended for one category ofsubscribers, such as subscribers in a northern area. The second feedconveyer feeds covers for books intended for subscribers who live inanother area, such as a southern area. Finally, a third feed mechanismis provided to feed covers which are suitable for either of the twocategories of subscribers. The third feed mechanism is activated intheevent of a malfunctioning of A first feed mechanism 52a is effective tofeed covers 440 to a cover conveyer assembly 42a. The first feedmechanism 52a includes a hopper type feeder 100 for depositing coversonto a conveyer 600. A second cover feed mechanism 90 is also effectiveto feed covers to the cover conveyer 42a. For example, the feedmechanism 52a feeds covers intended for northern subscribers while thefeed mechanism 90 feeds covers intended for southern subscribers. Ofcourse, the differences between the covers could be based uponsubscriber age, income, occupation, etc., as well as geographic locationof the subscriber.

The process computer a effects operation of the gatherer 12 to formcombinations of signatures which are in accordance with known subscribercriteria in the mannerdisclosed in the aforementioned Harder and Ranaapplication Ser. No. 141,331. The process computer 20a includes suitableregisters for keeping track of the different combinations of signatures.In addition the computer includes controls for activating a drivemechanism 94 to move a divert gate 96 between a position (shown in solidlines in FIG. 4) in which it is effective to direct covers from the feedmechanism 52a to the cover conveyer 42a and a position (shown in dashedlines in FIG. 4) in which the gate 96 is effective to direct covers fromthe feed mechanism 90 to the conveyer 42a.

When the divert gate 96 is in the raised position shown in solid linesin FIG. 4, a drive mechanism 98 is activated by the computer 20a to feeda first type of cover. When the divert gate 96 is in the loweredposition shown in dashed lines in FIG. 4, a drive mechanism 100 isactivated by the computer to feed a second type of cover. By controllingthe operation of the feed mechanisms 52a and 90 and the position of thegate96, the computer 20a is effective to have different covers,associated with different subscribers, transported to the coveringstation 46a in timed relationship with diferent combinations ofsignatures.

A detector 66a is associated with feed mechanisms 52a and 90 to detectmisfeeding or a double feed of covers by the feed mechanisms. If thedetector 66a detects a failure'of one of the feed mechanisms 62a or 90to feed a cover or the feeding of double covers, the process computer 20activates a third feed mechanism 106 to feed a standard cover which issuitable for any of the subscribers. In the event of a double feeding ofcovers by one of the cover feed mechanisms 52a or 90, a reject gate 77ais actuated by a drive mechanism 79a to reject the covers.

The computer 20 is effective to detect a malfunctioning of the gatherer12 in forming abook for association with a cover fed by either the firstcover feed mechanism 52a or the second cover feed mechanism 90. Thereject mechanism is activated by the computer 20 to reject the defectivebook. In addition, the computer 20 renders the cover feed mechanism 524or 90 ineffective to feed a cover for association with the rejectedbook. Of course, the computer 20 also renders the third feed 6 mechanism106 ineffective to feed a standard cover for association with therejected book.

In view of the foregoing description, it can be seen that the system 10includes a conveyer 42 which sequentially transports covers to acovering station 46. In the FIG. 2 embodiment, a first cover feedmechanism 52 is provided to feed covers to the cover conveyer 42. In theevent of a malfunctioning of the cover feed mechanism 52, a second coverfeed mechanism 56 is activated to feed a cover to the conveyer 42 sothat a continuous stream of covers is conducted to the covering station46. In'the FIG. 4 embodiment, cover feed mechanisms 52a or are utilizedto feed covers to the cover conveyer 42a. This enables books entitledfor different'subscribers tohave different covers. In the event of amalfunctioning in one of the cover feed mechanisms52a or 90, a thirdcover feed mechanism 106 is activated to feed a cover to the coverconveyer 42a. Although the binder 24 has been described herein inconnection with soft cover books, it is contemplated that it could beutilized for hard cover books.

Having described specific preferred embodiments of the invention, thefollowing is claimed:

1. An apparatus for use in covering books, said apparatus comprisingbook conveyer means for sequentially conveying a stream of books to acovering station, cover conveyer means for sequentially transporting astream of covers to the covering station, first cover feed means forsequentially feeding covers to said cover conveyer means, detector meansfor detecting a malfunction of said first cover feed means and resultingopening in the stream of covers, second cover feed means for feeding acover to said cover conveyer means at the opening resulting from themalfunctioning of said first cover feed means, and control means foractivating said second cover feed means to feed a cover to saidcover'conveyer means in response to detection of a malfunction of saidfirst cover feed means by said detector means.

2. An apparatus as set forth in claim 1 wherein said detector meansincludes means for detecting the feeding of double covers by said firstcover feed means-and wherein said apparatus further includes rejectmeans for rejecting double covers fedby said first cover feed means.

3. An apparatus as set forth in claim 1 wherein said detector meansincludes means for detecting a failure of said first cover means to feeda cover to said cover conveyer means.

4. An apparatus as set forth in claim 1 further including gatherer meansfor forming signatures into groups to make books, and reject means forrejecting a defective book, said control means including means forrendering said first and'second feed means ineffective to feed a coverfor association with the rejected book.

5. An apparatus for producing different books of different predeterminedcombinations of signatures for different subscribers in accordance withpredetermined criteria from known subscriber information, said apparatus comprising gatherer means for forming a combination of signaturesin accordance with known subscriber criteria, said gatherer meansincluding means for defining a plurality of feed stations, main conveyermeans for transporting groups of signatures, feed means at each of saidfeed stations for feeding signatures to said conveyer means, controlmeans for effecting operation of said feed means .to form different combinations of signatures for different subscribers, cover applicatormeans disposed at a covering station for applying a cover to each of thedifferent combinations of signatures, said main conveyer means beingeffective to sequentially transport the different combinations ofsignatures to the covering station, cover conveyer means forsequentially transporting covers to the covering station, first coverfeed means for sequentially feeding covers to said cover conveyor means,detector means for detecting a malfunction of said first cover feedmeans, and second cover feed means for feeding covers to said coverconveyer means, said control means including means for activating saidsecond cover feed means to feed a cover to said cover conveyer means inresponse to detection of a malfunction of said first cover feed means.

6. An apparatus as set forth in claim 4 further including third coverfeed means for feeding covers which are different than the covers fed bysaid first and second cover feed means, said control means includingmeans for efi'ecting operation of said first cover feed means to feedcovers to combinations of signatures for one group of subscribers andfor effecting operation of said third cover feed means to feed covers tocombinations of signatures for another group of subscribers.

7. An apparatus as set forth in claim 4 further including reject meansfor rejecting defective books formed as a result of a malfunctioning ofsaid gatherer means, said control means including means for renderingsaid first and second cover feed means ineffective to feed a cover forassociation with the rejected book.

1. An apparatus for use in covering books, said apparatus comprisingbook conveyer means for sequentially conveying a stream of books to acovering station, cover conveyer means for sequentially transporting astream of covers to the covering station, first cover feed means forsequentially feeding covers to said cover conveyer means, detector meansfor detecting a malfunctioN of said first cover feed means and resultingopening in the stream of covers, second cover feed means for feeding acover to said cover conveyer means at the opening resulting from themalfunctioning of said first cover feed means, and control means foractivating said second cover feed means to feed a cover to said coverconveyer means in response to detection of a malfunction of said firstcover feed means by said detector means.
 2. An apparatus as set forth inclaim 1 wherein said detector means includes means for detecting thefeeding of double covers by said first cover feed means and wherein saidapparatus further includes reject means for rejecting double covers fedby said first cover feed means.
 3. An apparatus as set forth in claim 1wherein said detector means includes means for detecting a failure ofsaid first cover means to feed a cover to said cover conveyer means. 4.An apparatus as set forth in claim 1 further including gatherer meansfor forming signatures into groups to make books, and reject means forrejecting a defective book, said control means including means forrendering said first and second feed means ineffective to feed a coverfor association with the rejected book.
 5. An apparatus for producingdifferent books of different predetermined combinations of signaturesfor different subscribers in accordance with predetermined criteria fromknown subscriber information, said apparatus comprising gatherer meansfor forming a combination of signatures in accordance with knownsubscriber criteria, said gatherer means including means for defining aplurality of feed stations, main conveyer means for transporting groupsof signatures, feed means at each of said feed stations for feedingsignatures to said conveyer means, control means for effecting operationof said feed means to form different combinations of signatures fordifferent subscribers, cover applicator means disposed at a coveringstation for applying a cover to each of the different combinations ofsignatures, said main conveyer means being effective to sequentiallytransport the different combinations of signatures to the coveringstation, cover conveyer means for sequentially transporting covers tothe covering station, first cover feed means for sequentially feedingcovers to said cover conveyor means, detector means for detecting amalfunction of said first cover feed means, and second cover feed meansfor feeding covers to said cover conveyer means, said control meansincluding means for activating said second cover feed means to feed acover to said cover conveyer means in response to detection of amalfunction of said first cover feed means.
 6. An apparatus as set forthin claim 4 further including third cover feed means for feeding coverswhich are different than the covers fed by said first and second coverfeed means, said control means including means for effecting operationof said first cover feed means to feed covers to combinations ofsignatures for one group of subscribers and for effecting operation ofsaid third cover feed means to feed covers to combinations of signaturesfor another group of subscribers.
 7. An apparatus as set forth in claim4 further including reject means for rejecting defective books formed asa result of a malfunctioning of said gatherer means, said control meansincluding means for rendering said first and second cover feed meansineffective to feed a cover for association with the rejected book.